USER S MANUAL. CNC Stepper Motor Control Box CS3EA4-1 Rev. 1

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1 USER S MANUAL CNC Stepper Motor Control Box CS3EA4-1 Rev. 1 April, 2012

2 USER'S MANUAL TABLE OF CONTENTS Page # Contents 1.0 FEATURES SPECIFICATIONS SYSTEM REQUIREMENTS WARNING CONTROL BOX DESCRIPTION Front Panel Description Back Panel Description Internal Layout QUICK START (STEP by step) Step 1. Connecting Motor cables Step 3. Connecting Limit switches Board Step 3. Connecting VFD Step 4. Coolant / Vacuum AC Plug Step 5. Connecting Probe Step 6. Connecting External E-Stop Step 7. Selecting the AC operting voltage Step 8. Software Installation: Step 9. Configuring the Pendant WIRING DIAGRAMS PART LIST PINOUT DISCLAIMER... 16

3 1.0 FEATURES Ethernet controlled CNC Stepper Control Box with microstepping. 3 Stepper Motor. Suitable for a wide range of stepping motors of Nema 17, 23 and 34. Up to 4.0A per Phase. On-Panel Emergency Stop Push Button (E-Stop). RJ45 Interface for VFD control (Variable Analog Output, Relay contact and 24VDC). Relay Controlled Coolant/Vacuum AC Plug. 1 Probe input. (Probe not included) 1 External E-Stop input. Works directly with Mach3.

4 2.0 SPECIFICATIONS Main Voltage Input (VAC) 110V or 220V - Switch selectable Main voltage for motors (VDC) Logic supply voltage (VDC) 5V and 24V Peak Current per axis (A) 5.6 Amp per Phase Step input frequency 0-200KHz Digital inputs (LOW) -0.5V - 0.8V Digital inputs (HIGH) 2V-5V Coolant/Vacuums output 110VAC@10A or 220VAC@7A Cooling 1 DC Fan Dimensions (mm) 430 X 142 X 380 Weight (lbs) / (kg) 3.0 SYSTEM REQUIREMENTS Processor 1Ghz CPU Memory 512 USB 1.1 or 2.0 Operating System Windows 2000, Windows XP, Windows Vista, or Windows 7 Software Mach3 Version R WARNING Electrical shock or serious physical injury could result due to misuse Control BOX. Disconnect power cables while installing the Control Box. Read and follow instructions on the manual. User s Manual Page 3

5 5.0 CONTROL BOX DESCRIPTION 5.1 Front Panel Description 5.2 Back Panel Description User s Manual Page 4

6 5.3 Internal Layout 6.0 QUICK START (STEP BY STEP) 6.1 Step 1. Connecting Motor cables. STEPPER MOTOR CABLE WIRE PIN DESCRIPTION COLOR 1 A+ RED 2 A- WHITE 3 B+ BLACK 4 B- GREEN User s Manual Page 5

7 6.2 Step 3. Connecting Limit switches Board. LIMIT SWITCHS CONNECTOR RJ45 PIN DESCRIPTION 1 GND 2 LPT1_13 3 LPT1_12 4 LPT1_11 5 NOT USED 6 NOT USED 7 5V 8 NOT USED Sample Wiring with mechanical switches. Sample Wiring with limit switches OMRON DSA-8514 Wiring is made to work with an A32 Switch Assembly, C16 Photo and Limit Board, a C45 LIMIT AND HOME UNIVERSAL, A61 Inductive Switch Assembly or a C27- Ethernet RJ45 Breakout Board, which could take any kind of switches, including inductive, capacitive, hall effect, optical, or mechanical. User s Manual Page 6

8 6.3 Step 3. Connecting VFD VFD CONNECTOR RJ45 PIN DESCRIPTION 1 ANALOG OUTPUT COMMON (ACM) 2 ANALOG OUTPUT (AVI) 3 NOT USED 4 RELAY 1 NO (Normally Open) CONTACT (CW) or (ON/OFF) 5 NOT USED 6 RELAY 2 NO (Normally Open) CONTACT (CWW) 7 24VDC Output 8 RELAYS COMMON CONTACTS (DCM) The box is prewired for INTERNATIONAL VFD Mode, if using on US mode, open the box and move the jumper on the C32. The true max and min speeds of the spindle must be set: 6.4 Step 4. Coolant / Vacuum AC Plug. Coolant / Vacuum are 110VAC/220VAC outputs controlled by electromechanical Relays. Note: Coolant / Vacuum output can be activated only if the spindle is ON. User s Manual Page 7

9 6.5 Step 5. Connecting Probe. Touch probes are wired and preconfigured and just needs to be connected to the back panel. CNC4PC offers this unit: but other may be used as long as the wiring is compatible, Refer to the product s documentation for additional information: Step 6. Connecting External E-Stop. The external e-stop is optional. If the plug is not present, the e-stop circuit will get closed. If the plug is put in place, a NC e-stop switch must be used. User s Manual Page 8

10 6.7 Step 7. Selecting the AC operting voltage Select the AC operating voltage by using the switch located in the power supply, close to this image. S E L E C T O P E R A T I N G V O L T A J E B E F O R E C O N N E C TIN G TO P O W E R. 6.8 Step 8. Software Installation: Before connecting the box to power install the basic software and configuration files: 1. Download and install Mach3: 2. Download and install the Ethernet Driver and Smooth Stepper Plugin: 3. Install the Mach3 License. 4. Download and copy XML and configuration files: Make sure to copy each file in the specific directory. 6.9 Step 9. Configuring the Pendant. 1. Configure Ports & Pins to use port 2 and pins 29 as inputs. User s Manual Page 9

11 2. Configure the Smooth Stepper Plugin to use pins 29 on port 2 as inputs: 3. Enable Output 6 on port 2 pin 1. User s Manual Page 10

12 4. Configure the MPG and ENCODER on port 2 pins 2 and 3 for channels A and B. 5. Configure the OEM Triggers as described in the image: User s Manual Page 11

13 6. Download, copy in to the Brains Directory and enable the following brains found HERE. 7. Set the Step Jog resolution: User s Manual Page 12

14 7.0 WIRING DIAGRAMS User s Manual Page 13

15 8.0 PART LIST QUANTITY COMPONENT 1 5VDC@3A Regulated Switching Power Supply 1 24VDC@1.3A Regulated Switching Power Supply 1 Latch Twist-Release E-Stop Button 1 C32R3 MULTIFUNCTION BREAKOUT BOARD 1 A2 - DB25 Gender Changer, DB25 pin Female to DB25 pin Female. 3 KL Driver 3 C34KLDR2- Driver to RJ45 Connector Board for Keling's Digital Drivers 1 A28-5 FT Booted Cat5e Network Patch Cable - Orange 1 A39-6 FT Power Cord- Standard System 5 A26-1 FT Booted Cat5e Network Patch Cable - Orange User s Manual Page 14

16 PINOUT PORT PIN CONTROL BOX FUNCTION MACH FUNCTION 1 1 NOT USED NOT USED 1 2 STEP X STEP PIN# 1 3 DIR X DIR PIN# 1 4 STEP Y STEP PIN# 1 5 DIR Y DIR PIN# 1 6 STEP Z STEP PIN# 1 7 DIR Z DIR PIN# 1 8 NOT USED NOT USED 1 9 NOT USED NOT USED 1 10 MACH E-STOP FUNTION ESTOP 1 11 LIMIT X X LIMIT Y Y LIMIT Z Z STEP SPINDLE (PWM) STEP PIN# 1 15 PROBE PROBE 1 16 DIR SPINDLE DIR PIN# 1 17 NOT USED NOT USED 2 1 NOT USED NOT USED 2 2 ENCODER A ENCODER 1 AND MPG#1 2 3 ENCODER B ENCODER 1 AND MPG#1 2 4 SELECT X (MPG) OEM TRIG #1 2 5 SELECT Y (MPG) OEM TRIG #2 2 6 SELECT Z (MPG) OEM TRIG #3 2 7 SELECT A (MPG) OEM TRIG #4 2 8 SELECT 1 (MPG) OEM TRIG #5 2 9 SELECT 10 (MPG) OEM TRIG # SELECT 100 (MPG) OEM TRIG # NOT USED NOT USED 2 12 SELECT 5(MPG) OEM TRIG # SELECT 6 (MPG) OEM TRIG # NOT USED NOT USED 2 15 NOT USED NOT USED 2 16 COOLANT / VACUUM OUTPUT # CHARGE PUMP CHARGE PUMP User s Manual Page 15

17 9.0 DISCLAIMER Use caution. CNC machines could be dangerous machines. DUNCAN USA, LLC or Arturo Duncan are not liable for any accidents resulting from the improper use of these devices. This product is not fail-safe device, and it should not be used in life support systems or in other devices where its failure or possible erratic operation could cause property damage, bodily injury or loss of life. User s Manual Page 16

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